Archive for September, 2008
Thursday, September 18th, 2008
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Thursday, September 18th, 2008
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Wednesday, September 17th, 2008
What a mess. I-95 covered with Nickels!
Here’s a link to the local reporting:
http://www.local6.com/news/17493097/detail.html?rss=orlpn&psp=news
Here’s the local reporting (WMV format):
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Wednesday, September 17th, 2008
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Wednesday, September 17th, 2008
Sanjay Gandhi, one of of TapRooT® Instructors, sent these photos of a recent 2-Day TapRooT® Incident Investigation and Root Cause Analysis Class held by ExxonMobil in Qatar.
If you need to schedule TapRooT® Training at your facility anywhere around the world, drop us a note at:
http://www.taproot.com/contact.php


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Wednesday, September 17th, 2008
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Tuesday, September 16th, 2008
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Tuesday, September 16th, 2008

It seems that “human error” may be a “cause” of the deadly train crash is California. We can all look at cell phone policies, human alertness/situational awareness, signal effectiveness, etc., and try to implement corrective actions to improve human performance. But a better question might be:
” Why is a single human action safeguard the only thing between life and death of hundreds of passengers?”
That is the question behind an article published by the Associated Press that pushes for advanced technology to automatically stop these kinds of accidents. The cost – about $2 Billion for nationwide implementation.
This is a real case where a cost benefit /Return on Investment calculation would be interesting. My guess is that with train accidents all over the country, it would be worthwhile – but this is only a guess without someone actually running the numbers.
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Tuesday, September 16th, 2008
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Tuesday, September 16th, 2008
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Monday, September 15th, 2008
Reported in a recent AP article: “The Metrolink spokeswoman who announced that a deadly train crash was caused by an engineer’s mistake resigned Monday because the railroad’s board had called her words “premature,” even though they were later backed up by investigators.” Using TapRooT® our investigators know that that this finding would only be a problem (Causal Factor) and not the root causes.
Denise Tyrrell made a swift announcement blaming the engineer driving the Metrolink train for failing to stop at a red light and causing the head-on crash while the National Transportation Safety Board members cautioned that they had not completed their investigation (AP Article).
Another report stated “Metrolink Engineer Texting With Teen moments Before Killer Commuter Crash”.
What comes to mind with these numerous responses is the role of company media relations and their role in high profile incidents. There appear to be two main actions that must be announced during such major incidents: interim correction actions in place to protect the public and disassociation of the incident to how the company actually runs.
With wreckage and recovery efforts in process and before the investigation has had a chance to really find out the problems and what the causes were, how does it benefit a company to assign human error immediately? Instead of finding the root causes to prevent or mitigate this type of incident from occurring, the parties involved got into a battle of who was right first. The investigation to the true root causes of the Metrolink incident has only just begun.
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Sunday, September 14th, 2008
From the Houston Chronicle:
Valero, the nation’s largest refiner, sent inspection crews to refineries in Texas City, Houston and Port Arthur. Day said late Saturday that they found no significant damage to production units, but the plants don’t have electrical power. Day said crews are working with power providers.
Valero’s refineries also are developing startup plans, but Day said they had no timetable for when startup will begin or how long those processes will take.
Exxon Mobil and other refiners also were assessing damage.
In a briefing in Washington, U.S. Homeland Security Secretary Michael Chertoff said he expects it will take another day to determine Ike’s full impact on refineries, but a report from Shell’s massive Deer Park refinery and chemical complex at the Houston Ship Channel suggested damage could turn out to be less than feared.
The U.S. Energy Department said Saturday that Ike prompted shutdowns of 14 refineries in Port Arthur, Houston, Texas City and Corpus Christi.
Those plants process a combined 3.8 million barrels a day, or 22 percent of the nation’s daily refining capacity. They include Exxon Mobil’s Baytown refinery, the nation’s largest, and BP’s Texas City plant, the second-largest.
Other Gulf Coast refineries were operating, though some at reduced levels.
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Sunday, September 14th, 2008

The Associated Press says that oil field deaths are “soaring.”
But what do the statistics really show?
According to the article, “deaths per year” rose from 72 in 2002 to 125 in 2006.
But is total deaths the right statistic to measure? Or should it be deaths per 200,000 worker-hours?
If you look at those stats, the death rate increased in the early 2000’s, but has dropped since then.
The article claims that lack of training, drug use, and a high-pressure environment – as well as more drilling – are the cause of the increased accidents.
The article seems to find causes without root cause analysis or adequate evaluation of the statistics.
One thing I’m sure of is that the TapRooT® Users in the oil patch are working hard to maintain excellent safety records – even with increased drilling activity and a “high-pressure environment.” The discussions at the 2008 TapRooT® Summit about sharing safety best practices and how to have a good safety culture will help them improve.
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Sunday, September 14th, 2008
See the list at:
http://www.hss.energy.gov/CSA/bulletins.html
Topics include:
- Counterfeit Square D Circuit Breakers
- Silica Dust Exposure
- Automated External Defibrillators
- Avoiding Unwanted Chemical Reactions
- Use of Tungsten Welding Rods Containing Thorium
- SLead Safety Awareness
- Hexavalent Chromium Update
- Compressed-Gas Cylinder Safety
- Preventing Eye Injuries
- Control and Release of Property: A Guide to Good Practices for the Control and Release of Property
- Gas Buildup in Drums
- Natural Gas Line Breaks
- Hazards of Nitrogen Asphyxiation in Confined Spaces
- Boiler Safety Valve Test Failures
- Potentially Defective Battery Chargers (UPDATE)
- Respiratory Protection Incidents
- Working Safely with Acids
- Significant Radioactive Leak at Sellafield Due to Operational Complacency
- Vertical-Rail Fall Protection
- Vigilance in New or Infrequent High-Hazard Operations
- Safe Management of Mercury (Hg)
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Saturday, September 13th, 2008
The new Eclipse 500 very light jet has had its certification process upheld by an independent committee. However, the review panel said that the FAA and Eclipse aviation:
“…should conduct a root cause analysis” of trim, trim actuator and fire extinguisher problems reported by operators.”
For more info, see:
http://www.avweb.com/avwebflash/news/EclipseCertificationUpheld_198780-1.html
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Saturday, September 13th, 2008
See:
http://www3.thestar.com/static/googlemaps/starmaps.html?xml=080905_workplacedeaths.xml
There you will find an interactive map of the workplace accidents in Ontario. Just click on the pushpins of the map (at the link) and get a brief report of each accident.

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Saturday, September 13th, 2008
From posting:
Winnipeg Regional Health Authority / WRHA (Winnipeg MB): “Reporting to the Regional Manager, Work Order Management within Manitoba eHealth, the incumbent is responsible for facilitating problem identification, root cause analysis, communication..
See:
http://www.eluta.ca/search?ptitle=Service+Management+Analyst&position=fb26bb6a34efabda36634a6bf270ed40&imo=1
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Friday, September 12th, 2008
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Friday, September 12th, 2008
As Houston packs up ahead of hurricane Ike, many Houston refineries (including several TapRooT® Users) are shutting down – impacting US gasoline prices. Oil refineries that either suspended production or are in the process of shutting down include Valero Energy Corp.’s Texas City, Port Arthur and Houston plants, ExxonMobil’s Baytown refinery, LyondellBasell’s Houston plant, Shell’s Deer Park complex, ConocoPhillips’ Sweeny facility, Marathon Oil Corp.’s Texas City refinery, and BP’s Texas City refinery.
Refineries in Corpus Christi were running normally Thursday.
Let’s all pray that the storm ends up being weaker than expected and that damage to the coast is less than anticipated.
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Friday, September 12th, 2008
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Friday, September 12th, 2008
From job posting:
Responsibilities:
• Participate / perform equipment / process optimization and validations
• Participate / perform discrepant material investigation / disposition
• Provide Quality Engineering support on the production floor, update existing inspection plans, test methods and SOPs
• Participate in sample size determination, statistical analysis, training and root cause analysis
• Participate in Process Failure Modes and Effects Analysis
• Participate in various manufacturing projects such as process development, cost reduction and quality modernization initiatives
• Collect, review, analyze and trend quality indicators for monthly and quarterly reviews
• Participate in problem solving teams using standardized investigation processes / tools
Requirements:
• Bachelor Degree in any Engineering related discipline
• Preferably certified quality engineer
• Minimum 3 – 4 years of related QA experience
• Good understanding of engineering and mathematics principles
• Ability to use inspection and measuring instruments such as smartscope, profile projector, light microscopes, calipers, micrometers
For more information, see:
http://jobscentral.com.sg/viewSimpleProfile.php?eid=31162&jid=140184
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Friday, September 12th, 2008

Ken Scott – A career at MSHA preceded Ken’s work teaching root cause analysis for System Improvements, Inc..
Recently Ken replied to the weblog article on what it took for the United States to change its mining safety practices and what it might take for China’s mining industry to change. There was so much history in one response that I wanted to share it with you (pictures were put in for the article):
It was interesting that you looked at this one explosion in Pa. You could have looked at hundreds of mine disasters over the last 100 years which resulted in thousands of miner deaths as examples of mine safety. The old saying, “mine legislation was written in blood of miners”. History shows that only after major mine disasters did our government act and institute mine legislation to improve mine safety.
The period from 1900 – 1910 was one of the bloodiest times in our mining history. Thousands were killed and injured as the nation’s mines expanded.

In 1907 the largest mine explosion in our history happened at the Monongah Mine, Monongah, WV. It killed around 362 men and boys (could not determine the exact number of deaths because no method existed for accounting for boys helping their fathers in the mines) and left over 300 widows. They could account for the number of mules because the number of mules was on their inventory. That explosion, and the many others during the decade, led to the formation of the US Bureau of Mines in 1910.
The Bureau of Mines was mainly a research and advisory agency with little authority. Advances were made in mine safety over the next 50 years, but they were slow and many accidents and disaster continued to occur.

Plus, during that time, we had the intervention and influence of mining unions that pressed for better health and safety in the mines. I’m sure their (union) involvement helped with some of the progress. Often, the single deaths that occurred almost daily in mining were not even news outside the small mining towns.
After other mine explosions, inundations, and mine roof failures, state and federal legislation was slowly changed and improved, but it always seemed to take a major disaster. Several bad mine disasters happened in the 50’s and 60’s as mechanization took place in the mines which led to the Coal Mine Act and formation of Mine Safety and Health Admin (MSHA). This legislation was the result of another disaster in WV.

In 1968 a coal mine explosion in Farmington, WV that killed 78 miners (many never recovered) led to the 1969 coal mine health and safety Act. It was changed again after another mine explosion in 1976 to include the M/NM industry.

Even today, changes in the present law seems to only take place after a major mine accident. Just this year, changes in mine seals, miner rescue chambers and mine rescue procedures, were enacted due to the mine explosion at the Sago mine in WV. As you can see, the government only gets involved due to public pressure and opinion and not always when the need is identified.

As for China, I’m not sure where to start. First of all, I’ve never make a trip to the country and only talked to some mining individuals that have toured there mines. I have had the opportunity to teach and work with delegations from China in the past when I was with MSHA. Generally, I would say that a major change or shift has to take place in their culture and attitude towards worker safety before advancements will take place. I know for a fact, China has the technology and the engineering needed to mine coal and other resources as well as we do in the States. We have had hundreds of delegations and government groups from China visit and tour out mines and we have sent many government groups and mining company individuals to share technology and information with China.
China has the engineers, equipment and know-how to do a better job. What they don’t seem to have is the same conviction to provide for miner safety and health as we have. I think China is going through the changes in human rights that we went through in the early 1900’s. The government attitude towards miner safety and human life will need to change. But as we know when it comes to human rights, China lags behind the world and what will have to change is beyond this email.
To give you one example of the attitude of mine officials regarding human care that I remember from my MSHA days was talking to one of our representatives that we sent to China. When he went into one of the underground mines in China, he noticed a miner sleeping (at least that what he thought at first) against the mine wall at the bottom of the mine shaft when he got off the elevator. He didn’t pay much attention at first and only until his trip out that evening, did it sink home. That afternoon on his way out, he noticed the same miner lying by the wall and asked what’s with the miner. He was told that the miner had died during the start of the shift. They would bring him out at the end of the shift when the turnover took place. They didn’t say that the death was a result of an accident, or give any detail, but one could only guess. It didn’t seem that urgent of a matter to bring the miner out.
Where do you start with such a culture? I’m sure improvements are taking place in China, but compared to here, they have a long was to go. I turned down a trip with a delegation to China for this very reason when I worked with the agency.
When I get back, I’ll will send you some info on mine disasters and deaths that have occurred in this country. When you look at how slow change came to this country, and the fact we have farther to go, maybe what happening in China doesn’t seem as hard to understand.

If you ever want to read a real life experience of a mine disaster (mine fire) get the book titled “Trapped, The 1909 Cherry Mine Disaster” by Karen Tintori. It makes for interesting reading on the airplanes.
(more…)
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Friday, September 12th, 2008
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Thursday, September 11th, 2008

“… it does appear the man was wearing safety equipment. He’s not sure if it was being used correctly or if the harness somehow failed.”
What does your fall protection audit include? … annual gear inspection? …annual training? What about actual task and area hook up for the gear? Does a 100% completion of training/refreshers and gear inspection indicate a good fall protection program?
(more…)
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Thursday, September 11th, 2008
In a recent article about the evaluation of the effectiveness of speed cameras saving lives, the UK Telegraph quoted Dr. Linda Mountain, Department of Engineering at Liverpool University:
“Speed cameras do reduce accidents but not quite as much as has sometimes been claimed.”
“I think it’s not reasonable to say that 100 lives a year are being saved.”
“The number has been overestimated by 50 per cent on the basis of our data. Nevertheless, that’s a worthwhile saving.”
Dr Mountain said the assessment methods used by the Government and police authorities to evaluate speed camera success failed to take account of random “bad luck” at notorious accident spots.
She said that clusters of accidents are not always caused by dangerous roads and can be caused purely by chance, which would mean the number of accidents would have fallen regardless of whether a camera is put there or not.
The study forming the basis of the Government claims looked at accident trends of all 4,100 camera sites in the UK.
It found that over a period of four years speed cameras were responsible for a 22 per cent drop in the number of accidents.
The number of people killed or seriously injured was said to have fallen by 42 per cent, amounting to around 100 lives.
Dr Mountain, however, re-examined the evidence, conducting a new study looking at road accident numbers before and after cameras were installed at 215 sites.
She used an alternative analysis method, which took into account the element of uncertainty, resulting in a 19 per cent reduction.
Not allowing for this element would have indicated a reduction of 50%.
Dr Mountain added:
“If accidents fall dramatically after the cameras are in place, it could be that the cameras have reduced accidents – but some of the fall may simply show that a run of bad luck has come to an end.”
How do you measure the improvements of you performance improvement efforts?
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Thursday, September 11th, 2008
Associated Press and CNN report that OSHA has proposed fines of $14,000 after the investigation of a crane collapse at Kansas City Power & Light’s Iatan Power Plant in Platte County. For more information, see:
http://money.cnn.com/news/newsfeeds/articles/apwire/1adee9cedad143462499636385c4aad7.htm
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Thursday, September 11th, 2008
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Thursday, September 11th, 2008
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Wednesday, September 10th, 2008
Heidi Reed, one of our TapRooT® Instructors, sent these picture of students working on exercises at a recent on-site course.



Need an on-site course at your site to improve your employees root cause analysis and incident investigation skills?
Call us at 865-539-2139. Or e-mail us. Or see the course descriptions at:
http://www.taproot.com/courses.php
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Wednesday, September 10th, 2008

George Burk, plane crash and burn survivor, spoke at our Summit several years ago. The story of his survival ordeal is impressive.
Today he sent me a link to a tape of one of his original accident investigation interviews. Click on the link and hear the actual interview of a man who they thought would died at any time from his injuries. To read the story of his ordeal, order the book:
A Bridge Never Crossed
George is truly an inspiration. You can hear him struggle in pain to answer the investigator’s questions. Deep inside, he knew he was dying – yet he continued to struggle to answer their questions. He even throws in a occasional “Yes Sir!”
The questioning techniques used are rather rudimentary. If you would like to learn an advanced interviewing technique, attend a 5-Day TapRooT® Advanced Root Cause Analysis Team Leader Course and learn the TapRooT® 14-step cognitive interviewing process. For more information about the 5-Day Course, see:
http://www.taproot.com/courses.php?d=2
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Tuesday, September 9th, 2008

West Pittston Shaft Explosion. August 24, 1936.
Caption: “Mine blast victims are brought to the surface.” Five miners were killed in West Pittston Monday when an explosion wrecked a shaft of the Sullivan Trail Coal Company mine, 120 feet underground. The bodies are being brought to the surface while other miners look on.”
To see more historic mining incidents: (http://www.hsp.org/default.aspx?id=267).
After hearing about the China mine explosion last week and recently visiting a mine in New Mexico, I wondered what was the big step change that initiated the Legislative History of the Federal Mine Safety and Health Act of 1977 and the Federal Coal Mine Health and Safety Act of 1969? Will it take a bigger step change in China? What are your thoughts?
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Tuesday, September 9th, 2008
“A gas explosion at a mine killed 24 people and injured six Thursday in northeast China, state media said.”
“China’s coal mines are the world’s deadliest, with numerous fires, floods and other disasters killing an average of 13 miners a day.”
See: http://www.iht.com/articles/ap/2008/09/04/asia/AS-China-Mine-Accident.php
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Tuesday, September 9th, 2008
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